Load bearing device

ABSTRACT

A load bearing device for protectively packaging articles. The load bearing device interfaces with the corner of a shipping container on an outer surface and a corner of the article to be protected on an inner surface. The load bearing device may be formed of molded plastic and has the geometric contour of a pyramidical envelope. In one embodiment, the load bearing device includes a plurality of fluted elements fashioning a series of truncated triangular pyramids formed one into the other. The apices of the truncated pyramids consecutively increase in height in straight line fashion along the pyramid envelope to a centroidally positioned triangular pyramid.

United States Patent Kaplan 1 Mar. 11, 1975 LOAD BEARING DEVICE Primary Examiner-William 1. Price Assistant ExaminerDouglas B. Farrow [75] lnvemor' Paul Lwmgston Attorney, Agent, or Firm-Richard A. Dannells; Barry [73] Assignee: Air Products and Chemicals, Inc., Moyerman Allentown, Pa.

[22] F1led. June 7, 1973 [57] ABSTRACT [21] Appl. No.: 367,763 I A load bearmg dev1ce for protectively packagmg artlcles. The load bearing device interfaces with the corl l Cl 206/523, 229/14 C ner of a shipping container on an outer surface and a Int. Cl. corner of the article {0 be protected on an inner u of Search C, l; face. The ad bearing device may be formed of 217/53; 206/521, 523; 248/345-1 molded plastic and has the geometric contour of a pyramidical envelope. in one embodiment, the load Referehces Cited bearing device includes a plurality of fluted elements UNITED STATES PATENTS fashioning a series of truncated triangular pyramids 3,030,728 4/1962 Wesman 248/3451 formed one into the Other- The aPices of the truncated 3,047,142 7/1962 Heffley 229/14 c Py consecutively increase in height in Straight 3,049,260 8/1962 Stone .1 206/521 line fashion along the pyramid n p t a ntr 3,655.11 4/!972 Carroll 229/14 C dally positioned triangular pyramid. 3,762,626 10/1973 1 Dorsey 229/DlGv l AAW 17 Claims, 10 Drawing Figures PATENTEDHARI 1197s 3.870.152

' sum 1. or 3 LOAD BEARING DEVICE BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of protectively packaging articles. In particular this invention pertains to the field of corner'pads interposed between the corners of an article to be protected and the corners of a shipping container. More in particular, this invention pertains to a corner pad having a triangular pyramid envelope and being formed of fluted elements.

2. Prior Art Load bearing device formed into corner pads for protectively packaging articles are known in the art. However, some prior corner pads, such as that shown and described in U.S. Pat. No. 3,404,827 interface throughout their inner surface with the article to be protected, and throughout their outer surface with the corner surfaces of the shipping container. Dynamic loads are transmitted throughout the corner pad surface area, consequently leading to a large volume of material necessarily being used in order to absorb the imparted dynamic forces. In other prior corner pads, such as that shown in U.S. Pat. No. 3,049,260, triangular pyramid contours are utilized. However, such devices do not include surfaces formed of fluted elements and shock loading forces must be absorbed throughout the pad surface area. Further, devices such as that shown in the referenced patent are constructed of expanded cellular plastic material which usually provides protection for only one impact loading.

Other corner protector devices, such as that shown in U.S. Pat. No. 3,047,142 provide hollow rib elements extending above the surface of the device. However, such rib elements would only contact the container corner surface and not the article to be protected. Thus anyshock loading applied in between the rib elements would be directly transmitted to the article being protected. Other prior devices, such as that shown U.S. Pat. No. 2,805,810 are formed of corrugated'board material. However, in such cases, once impact is made the board material is usually permanently deformed and not further usable as a shock load absorber. Other prior pad assemblies such as that shown in U.S. Pat. No. 3,072,393 utilize resilient materials covered by rigid surfaces. However, such devices are complex in construction and comparatively expensive to manufacture. Further, in such devices, the impact load is still absorbed throughout the entire surfaces of the rigid outer coverings.

In some prior protective packages, such as that shown in U.S. Pat. No. 3,664,571, chevron shaped blanks are used to protect articles enclosed therein. However, such devices generally have opposing triangular sections which interface along scored intersection lines with other contoured sections of the package. Such devices are not adaptable for use in corners as protective padding. Further, the intersection score lines provide stress lines which could not be usable under high dynamic force loads. I

SUMMARY OF THE INVENTION A load bearing device for protectively packaging articles inserted therein. The device comprises a plurality of fluted elements forming a peripheral outer surface. The outer surface has a pyramidical envelope geometrical contour.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top view of the fluted load bearing device showing a structural rib element joining the fluted elements;

FIG. 2 is a front view of the load bearing device shown in FIG. 1;

FIG. 3 is a side view of the load bearing device;

FIG. 4 is a bottom view of the load bearing device showing the inner surface of the device;

FIG. 5 is a perspective view of the load bearing device mounted on the corner of an article to be protectively packaged;

FIG. 6 is a front view of the load bearing device without structural rib reinforcement;

FIG. 7 is a schematic view of the fluted elements having sharp angled upper and lower load bearing ridges;

FIG. 8 is a schematic view of the fluted elements having sharp angled upper load bearing ridges and rounded lower load bearing ridges;

FIG. 9 is a schematic view of the fluted elements having rounded upper and lower load bearing ridges; and,

FIG. 10 is a front view of an embodiment of the load bearing device having horizontally extended fluted elements.

-DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIGS. 1, 2, 3, 4 and 5, there is shown load bearing device or corner pad 10 to be used for protectively packaging furniture, appliances or other articles 12. In general use, the corners of articles 12 are inserted withindevice 10 and mated in contiguous relation thereto. Article 12 in combination with pads 10 mounted on 'the'corners, is then inserted into a shipping container for transportation. Device 10 is thus interposed between article 12 and a shipping container in order to effectively deminish dynamic or shock load forces which may be transmitted to article 12 during the movement of the shipping container.

Due to the unique geometrically contoured construction of load bearing device 10, to be described in the following paragraphs, impact forces are directed to specific pressure points to be diffused as the result of pleated construction. Similarly, impact on a surface of device 10 may be transmitted to specific ridges for partially dissipating the impact force.

As is shown in FIGS. 1, 2, and 3, device 10 is formed of a plurality of fluted elements 14 which form peripheral outer surface 16. In general, device 10 outer surface 16 as shown in FIG. 2 has a pyramidical envelope surface contour. Fluted elements 14 form outer surface 16 and inner surfacw 18, shown in FIG. 4, into an undulating or pleated wall surface. In effect, fluted elements 14 take the form of extended tooth members rising from base plane 20 to element apex 22.

The pyramidical envelope of device 10 forms a triangular pyramid envelope having three contiguous faces 24, 26 and 28 which define inner and outer surface 18 and 16 respectively. Faces 24, 26 and 28 are defined by intersection line 30 (shown dotted in FIG. 2). As can be seen, each of fluted elements 14 pass from base plane 20 to an individual apex 22. The height of apices 22 monotonically increase in straight line fashion such that intersection line 30 may be drawn through apex 22 thus defining faces 24, 26 and 28. Imaginary intersection line 30 may be extended from base plane 20 to centroidally located apex 22', thus dividing the pyramidical envelope into three surface envelope triangles which are equal angled.

In general, fluted elements 14 on each of contiguous faces 24, 26 28 are parallely disposed each to the other and extend from base plane 20 to an individual apex 22 in a substantially vertical direction as seen in FIG. 2. Each fluted element is trough shaped having load bearing ridge 32 passing from base plane 20 to apex 22. Ridge 32 may then contact or interface with the shipping container at the three perpendicular surfaces defining a shipping container corner.

Each of fluted elements 14 is thus defined by a pair of inclined walls 34, 36 which interface at load bearing ridge 32 throughout flute extension from base plane 20 to apex 22. Inclined wall 34 of one flute element 14 interface with inclined wall 36 of a next consecutive flute element 14 to form lower ridge 38 which forms a load bearing surface between device and article 12 when article 12 is inserted therein. In the manner thus described, a trough shaped buffer zone or air space is created between the shipping container and article 12.

In further description of the geometrical contour of load bearing device 10, it is seen in FIG. 1, that each fluted element 14 forms a common apex 22 on intersection line 30 with another element 14 of an adjacent face 24, 26, or 28. Additionally, each pair of fluted elements 14 are joined into a next succeeding element 14 through connecting ridge 40. Thus it is seen that the overall contour of device 10 is constructed of a plurality of pyramid contours of varying height, joined in spaced relation to a next succeding pyramid contour. Additionally, it should be noted that centroidally located apex 22' is formed by the intersection of three ridges 38 on each of said adjacent contiguous faces 24, 26 and 28.

In order to add additional structural integrity to device 10, structural rib element 42 may be formed as a part of the peripheral surface of pad 10. As shown in FIGS. 1, 2 and 3 rib element 42 passes in a plane substantially parallel to base plane 20. Rib element 42 further extends in a direction substantially normal to the extension of fluted elements 14. Structural rib element is joined to consecutively spaced fluted elements 14 through upper tab elements 44 (shown in FIG. 1) and lower tab elements 46 (shown in FIG. 2) as well as structural rib ridge 48 which provides for the interface joining of tab elements 44 and 46. Although structural rib element 42 may be added to load bearing device 10 in order to improve the structural integrity, it should be noted that device 10 may be formed without rib element 42 as is shown in FIG. 6.

Load bearing device 10 may include base surface 50 formed within base plane 20. Base member 50 joins opposing inclined walls 34, 36 of consecutive fluted elements 14. Member 50 passes around the perimeter of device 10, thus possibly providing some additional structural integrity of device 10 while providing a base surface to which the lower end of each fluted element 14 may be joined.

In general, load bearing device 10 is constructed of a thermosplastic material with flex such as linear polyethylene, conventional polyethylene, polypropylene, acetate, vinyl or some like material. In construction load bearing device may be formed in a one-piece unitary structure. Manufacture may be achieved through a number of conventional, well known forming and molding techniques such as injection molding, blow molding, rotational molding, pressure forming, thermo forming or some like technique.

FIG. 10, details an embodiment of corner pad or load bearing device 10 where the pyramidical envelope is developed by horizontally directed fluted elements or pleated members 14. The length of each fluted element 14 diminishes monotonically in straight line fashion from a mixium length at base plane 20 to a minium in the fluted element 14 nearest to centroidally located apex 22'. Intersection line 30, passing through each of the apices 22 of the plurality of fluted elements 14, defines the interface between the three faces forming the pyramidical envelope.

In this embodiment of the invention, each fluted member 14' includes a pair of inclined walls 34' and 36' which intersect and are joined in one piece construction along load bearing ridge 32'. Load bearing ridge 32 contacts the shipping container. Lower bearing ridge 38' is formed at the horizontal interface between inclined walls 34 and 36 of consecutively arranged flute members 14. Lower bearing ridge 38 interfaces with article 12 on a lower surface thereof. In this manner, load bearing device 10' may be interposed between article 12 and the shipping container for reducing any shock load forces transmitted to article 12.

FIGS. 7, 8, and 9 depict different geometrical configurations for fluted elements 14. In FIG. 7 it is seen that inclined walls 34 and 36 interface with each other in substantially straight line fashion. Thus, upper load bearing ridge 32 and lower ridge 38 form substantially triangular sections with inclined walls 34 and 36. In FIG. 8, lower ridge 38 is given a larger radius of curvature while opposing inclined walls 34 and 36 interface at load bearing ridge 32 in a pointed manner. In FIG. 9, both upper and lower ridges 32' and 38 are formed having a large radius of curvature. By using a combination of geometric contours for fluted element ridges 32 and 38, it has been seen that the flexability or rigidity of load bearing device 10 may be adjusted through a wide range of values.

It is to be understood that the load bearing capability of device or corner pad 10 may be varied dependent upon an adjustment of pad physical parameters without changing the inventive concept as herein detailed. Thus, the rigidity and flexibility of pad 10 may be varied by increasing the wall thickness between outer surface 16 and inner surface 18. The durometer detailing the hardness or softness of a particular resinous-plastic material used in forming pad 10 will similarly affect the load bearing capabilities. Further, geometric variations may be employed to adjust flexibility such as angle modifications between fluted elements 14 as well rib elements 42. Thus, increased angles between flute 14 and ribs 42 will provide more flexibility whereas more acute angles will increase the rigidity of device 10.

A latitude of modification, change and substitution is intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

What is claimed is:

1. A load bearing device for protectively packaging articles inserted therein formed of moldable plastic and comprising a plurality of fluted elements forming a peripheral outer surface and an undulating inner surface of said load bearing device,

said outer surface. having a pyramidical envelope geometrical contour, said pyramidical contour envelope forming a triangular pyramid envelope having three contiguous faces defining said inner and outer surfaces of said load bearing device,each of said fluted elements passing to an apex defining an intersection between adjac. .l'[ faces of said pyramidical contour envelope, a pair of fluted elements on adjacent faces of said pyramidical contour envelope forming a common apex on said intersection line between said adjacent faces,

said fluted element apices forming a monotonically increasing-positional location along said intersecting line from a base plane of said load bearing device to a geometrical centroidally located apex of said pyramid envelope,

said fluted elements on each of said faces of said load bearing device being defined by a pair of walls interfacing at a load bearing ridge extending substantially parallel each to the other.

2. The load bearing device as recited in claim 1 wherein said fluted elements extend in a direction substantially parallel to said base plane.

3. The load bearing device as recited in claim 2 wherein each of said fluted elements is secured to a next consecutive fluted element throughout said extension.

4. The load bearing device as recited in claim 2 wherein each of said pyramid faces is formed in a onepiece unitary structure.

5. The load bearing device as recited in claim 2 wherein said adjacent faces of said device are formed each to the other in a one-piece unitary structure.

6. The load bearing device as recited in claim 2 including at least one structural rib element formed within at least one of said faces, said structural rib element extending in a direction substantially normal to said extension of said fluted elements.

7. The load bearing device as recited in claim 6 wherein said structural rib element extends from said base plane to said geometrical centroidedly located apex of said pyramid envelope.

8. The load bearing device as recited in claim 1 wherein said fluted elements extend in a substantially vertical direction at a predetermined angle to said base plane.

9. The load bearing device as recited in claim 8 wherein each of said fluted elements is secured to a next consecutive fluted element throughout said extension.

10. The load bearing device as recited in claim 8 wherein each of said pyramid faces is formed in a onepiece unitary structure.

11. The load bearing device as recited in claim 8 wherein said adjacent faces of said device are formed each to the other in a one-piece unitary structurel 12. The load bearing device as recited in claim 8 including at least one structural rib element formed within at least one of said faces, said structural rib element extending in a direction substantially normal to said extension of said fluted elements.

13. The load bearing device as recited in claim 12 wherein said structural rib element extends throughout said peripheral outer surface forming a closed contour thereon.

14. A corner pad article of manufacture formed in a one-piece unitary structure for being interposed between a shipping container corner and a corner of an article to be protectively packaged, said corner pad including a contour envelope approximating a triangular pyramid, said corner pad being formed of a plurality of fluted elements providing a multiplicity of truncated triangular pyramids formed each into the other, each of said truncated triangular pyramids having a vertically directed apex, said apices of said truncated triangular pyramids consecutively increasing in height in straight line fashion along said pyramid envelope to a centroidally positioned triangular pyramid.

15. The corner pad article of manufacture as recited in claim 14 wherein said fluted elements form an undulating inner and outer surface of said corner pad, said inner surface forming a contour envelope approximately a triangular pyramid.

16. The corner pad article of manufacture as recited in claim 14 including at least one structural rib element formed within said surface of said corner pad, said structural rib element joining consecutively spaced fluted elements each to the other.

17. The corner pad article or manufacture as recited in claim 16 wherein said structural rib element passes substantially normal to the extension of said fluted elements. 

1. A load bearing device for protectively packaging articles inserted therein formed of moldable plastic and comprising a plurality of fluted elements forming a peripheral outer surface and an undulating inner surface of said load bearing device, said outer surface having a pyramidical envelope geometrical contour, said pyramidical contour envelope forming a triangular pyramid envelope having three contiguous faces defining said inner and outer surfaces of said load bearing device, each of said fluted elements passing to an apex defining an intersection between adjacent faces of said pyramidical contour envelope, a pair of fluted elements on adjacent faces of said pyramidical contour envelope forming a common apex on said intersection line between said adjacent faces, said fluted element apices forming a monotonically increasing positional location along said intersecting line from a base plane of said load bearing device to a geometrical centroidally located apex of said pyramid envelope, said fluted elements on each of said faces of said load bearing device being defined by a pair of walls interfacing at a load bearing ridge extending substantially parallel each to the other.
 1. A load bearing device for protectively packaging articles inserted therein formed of moldable plastic and comprising a plurality of fluted elements forming a peripheral outer surface and an undulating inner surface of said load bearing device, said outer surface having a pyramidical envelope geometrical contour, said pyramidical contour envelope forming a triangular pyramid envelope having three contiguous faces defining said inner and outer surfaces of said load bearing device, each of said fluted elements passing to an apex defining an intersection between adjacent faces of said pyramidical contour envelope, a pair of fluted elements on adjacent faces of said pyramidical contour envelope forming a common apex on said intersection line between said adjacent faces, said fluted element apices forming a monotonically increasing positional location along said intersecting line from a base plane of said load bearing device to a geometrical centroidally located apex of said pyramid envelope, said fluted elements on each of said faces of said load bearing device being defined by a pair of walls interfacing at a load bearing ridge extending substantially parallel each to the other.
 2. The load bearing device as recited in claim 1 wherein saiD fluted elements extend in a direction substantially parallel to said base plane.
 3. The load bearing device as recited in claim 2 wherein each of said fluted elements is secured to a next consecutive fluted element throughout said extension.
 4. The load bearing device as recited in claim 2 wherein each of said pyramid faces is formed in a one-piece unitary structure.
 5. The load bearing device as recited in claim 2 wherein said adjacent faces of said device are formed each to the other in a one-piece unitary structure.
 6. The load bearing device as recited in claim 2 including at least one structural rib element formed within at least one of said faces, said structural rib element extending in a direction substantially normal to said extension of said fluted elements.
 7. The load bearing device as recited in claim 6 wherein said structural rib element extends from said base plane to said geometrical centroidedly located apex of said pyramid envelope.
 8. The load bearing device as recited in claim 1 wherein said fluted elements extend in a substantially vertical direction at a predetermined angle to said base plane.
 9. The load bearing device as recited in claim 8 wherein each of said fluted elements is secured to a next consecutive fluted element throughout said extension.
 10. The load bearing device as recited in claim 8 wherein each of said pyramid faces is formed in a one-piece unitary structure.
 11. The load bearing device as recited in claim 8 wherein said adjacent faces of said device are formed each to the other in a one-piece unitary structure.
 12. The load bearing device as recited in claim 8 including at least one structural rib element formed within at least one of said faces, said structural rib element extending in a direction substantially normal to said extension of said fluted elements.
 13. The load bearing device as recited in claim 12 wherein said structural rib element extends throughout said peripheral outer surface forming a closed contour thereon.
 14. A corner pad article of manufacture formed in a one-piece unitary structure for being interposed between a shipping container corner and a corner of an article to be protectively packaged, said corner pad including a contour envelope approximating a triangular pyramid, said corner pad being formed of a plurality of fluted elements providing a multiplicity of truncated triangular pyramids formed each into the other, each of said truncated triangular pyramids having a vertically directed apex, said apices of said truncated triangular pyramids consecutively increasing in height in straight line fashion along said pyramid envelope to a centroidally positioned triangular pyramid.
 15. The corner pad article of manufacture as recited in claim 14 wherein said fluted elements form an undulating inner and outer surface of said corner pad, said inner surface forming a contour envelope approximately a triangular pyramid.
 16. The corner pad article of manufacture as recited in claim 14 including at least one structural rib element formed within said surface of said corner pad, said structural rib element joining consecutively spaced fluted elements each to the other. 